Abstract: Tailor-welded Blanks (TWBs) are tailor made for
different complex component designs by welding multiple metal
sheets with different thicknesses, shapes, coatings or strengths prior
to forming. In this study the Hemispherical Die Stretching (HDS) test
(out-of-plane stretching) of TWBs were simulated via
ABAQUS/Explicit to obtain the Forming Limit Diagrams (FLDs) of
Stainless steel (AISI 304) laser welded blanks with different
thicknesses. Two criteria were used to detect the start of necking to
determine the FLD for TWBs and parent sheet metals. These two
criteria are the second derivatives of the major and thickness strains
that are given from the strain history of simulation. In the other word,
in these criteria necking starts when the second derivative of
thickness or major strain reaches its maximum. With having the time
of onset necking, one can measure the major and minor strains at the
critical area and determine the forming limit curve.
Abstract: Gas Metal Arc Welding (GMAW) processes is an
important joining process widely used in metal fabrication
industries. This paper addresses modeling and optimization of this
technique using a set of experimental data and regression analysis.
The set of experimental data has been used to assess the influence
of GMAW process parameters in weld bead geometry. The
process variables considered here include voltage (V); wire feed
rate (F); torch Angle (A); welding speed (S) and nozzle-to-plate
distance (D). The process output characteristics include weld bead
height, width and penetration. The Taguchi method and regression
modeling are used in order to establish the relationships between
input and output parameters. The adequacy of the model is
evaluated using analysis of variance (ANOVA) technique. In the
next stage, the proposed model is embedded into a Simulated
Annealing (SA) algorithm to optimize the GMAW process
parameters. The objective is to determine a suitable set of process
parameters that can produce desired bead geometry, considering
the ranges of the process parameters. Computational results prove
the effectiveness of the proposed model and optimization
procedure.
Abstract: A three-dimensional finite element modeling for austenitic stainless steel AISI 304 annealed condition sheets of 1.0 mm thickness are developed using ABAQUS® software. This includes spot welded and weld bonded joints models. Both models undergo thermal heat caused by spot welding process and then are subjected to axial load up to the failure point. The properties of elastic and plastic regions, modulus of elasticity, fracture limit, nugget and heat affected zones are determined. Complete loaddisplacement curve for each joining model is obtained and compared with the experiment data and with the finite element models without including the effect of thermal process. In general, the results obtained for both spot welded and weld-bonded joints affected by thermal process showed an excellent agreement with the experimental data.
Abstract: Bead-on-plate welds were carried out on AISI 316L
(N) austenitic stainless steel (ASS) using flux cored arc welding
(FCAW) process. The bead on plates weld was conducted as per L25
orthogonal array. In this paper, the weld bead geometry such as depth
of penetration (DOP), bead width (BW) and weld reinforcement (R)
of AISI 316L (N) ASS are investigated. Taguchi approach is used as
statistical design of experiment (DOE) technique for optimizing the
selected welding input parameters. Grey relational analysis and
desirability approach are applied to optimize the input parameters
considering multiple output variables simultaneously. Confirmation
experiment has also been conducted to validate the optimized
parameters.
Abstract: Ti-6Al-4V alloy has demonstrated a high strength to
weight ratio as well as good properties at high temperature. The
successful application of the alloy in some important areas depends
on suitable joining techniques. Friction welding has many
advantageous features to be chosen for joining Titanium alloys. The
present work investigates the feasibility of producing similar metal
joints of this Titanium alloy by rotary friction welding method. The
joints are produced at three different speeds and the performances of
the welded joints are evaluated by conducting microstructure studies,
Vickers Hardness and tensile tests at the joints. It is found that the
weld joints produced are sound and the ductile fractures in the tensile
weld specimens occur at locations away from the welded joints. It is
also found that a rotational speed of 1500 RPM can produce a very
good weld, with other parameters kept constant.
Abstract: The demand of hydrocarbons has increased the
construction of pipelines and the protection of the physical and
mechanical integrity of the already existing infrastructure. Corrosion
is the main reason of failures in the pipeline and it is mostly produced
by acid (HCOOCH3). In this basis, a CFD code was used, in order to
study the corrosion of internal wall of hydrocarbons pipeline. In this
situation, the corrosion phenomenon shows a growing deposit, which
causes defect damages (welding or fabrication) at diverse positions
along the pipeline. The solution of the pipeline corrosion is based on
the diminution of the Naphthenic acid.
Abstract: Friction-stir welding has received a huge interest in the last few years. The many advantages of this promising process have led researchers to present different theoretical and experimental explanation of the process. The way to quantitatively and qualitatively control the different parameters of the friction-stir welding process has not been paved. In this study, a refined energybased model that estimates the energy generated due to friction and plastic deformation is presented. The effect of the plastic deformation at low energy levels is significant and hence a scale factor is introduced to control its effect. The predicted heat energy and the obtained maximum temperature using our model are compared to the theoretical and experimental results available in the literature and a good agreement is obtained. The model is applied to AA6000 and AA7000 series.
Abstract: Arc welding is an important joining process widely used in many industrial applications including production of automobile, ships structures and metal tanks. In welding process, the moving electrode causes highly non-uniform temperature distribution that leads to residual stresses and different deviations, especially buckling distortions in thin plates. In order to control the deviations and increase the quality of welded plates, a fixture can be used as a practical and low cost method with high efficiency. In this study, a coupled thermo-mechanical finite element model is coded in the software ANSYS to simulate the behavior of thin plates located by a 3-2-1 positioning system during the welding process. Computational results are compared with recent similar works to validate the finite element models. The agreement between the result of proposed model and other reported data proves that finite element modeling can accurately predict the behavior of welded thin plates.
Abstract: This paper addresses the problem of recognizing and
interpreting the behavior of human workers in industrial
environments for the purpose of integrating humans in software
controlled manufacturing environments. In this work we propose a
generic concept in order to derive solutions for task-related manual
production applications. Thus, we are able to use a versatile concept
providing flexible components and being less restricted to a specific
problem or application. We instantiate our concept in a spot welding
scenario in which the behavior of a human worker is interpreted
when performing a welding task with a hand welding gun. We
acquire signals from inertial sensors, video cameras and triggers and
recognize atomic actions by using pose data from a marker based
video tracking system and movement data from inertial sensors.
Recognized atomic actions are analyzed on a higher evaluation level
by a finite state machine.
Abstract: In medical therapy, laser has been widely used to conduct cosmetic, tumor and other treatments. During the process of laser irradiation, there may be thermal damage caused by excessive laser exposure. Thus, the establishment of a complete thermal analysis model is clinically helpful to physicians in reference data. In this study, porcine liver in place of tissue was subjected to laser irradiation to set up the experimental data considering the explored impact on surface thermal field and thermal damage region under different conditions of power, laser irradiation time, and distance between laser and porcine liver. In the experimental process, the surface temperature distribution of the porcine lever was measured by the infrared thermal imager. In the part of simulation, the bio heat transfer Pennes-s equation was solved by software SYSWELD applying in welding process. The double ellipsoid function as a laser source term is firstly considered in the prediction for surface thermal field and internal tissue damage. The simulation results are compared with the experimental data to validate the mathematical model established here in.
Abstract: Among all mechanical joining processes, welding has
been employed for its advantage in design flexibility, cost saving,
reduced overall weight and enhanced structural performance.
However, for structures made of relatively thin components, welding
can introduce significant buckling distortion which causes loss of
dimensional control, structural integrity and increased fabrication
costs. Different parameters can affect buckling behavior of welded
thin structures such as, heat input, welding sequence, dimension of
structure. In this work, a 3-D thermo elastic-viscoplastic finite
element analysis technique is applied to evaluate the effect of shell
dimensions on buckling behavior and entropy generation of welded
thin shells. Also, in the present work, the approximated longitudinal
transient stresses which produced in each time step, is applied to the
3D-eigenvalue analysis to ratify predicted buckling time and
corresponding eigenmode. Besides, the possibility of buckling
prediction by entropy generation at each time is investigated and it is
found that one can predict time of buckling with drawing entropy
generation versus out of plane deformation. The results of finite
element analysis show that the length, span and thickness of welded
thin shells affect the number of local buckling, mode shape of global
buckling and post-buckling behavior of welded thin shells.
Abstract: The paper deals with determination of electromagnetic
and temperature field distribution of induction heating system used
for pipe brazing. The problem is considered as coupled – time
harmonic electromagnetic and transient thermal field. It has been
solved using finite element method. The detailed maps of
electromagnetic and thermal field distribution have been obtained.
The good understanding of the processes in the considered system
ensures possibilities for control, management and increasing the
efficiency of the welding process.
Abstract: The objective of this project is to produce computer
assisted instruction(CAI) for welding and brazing in order to
determine the efficiency of the instruction package and the study
accomplishment of learner by studying through computer assisted
instruction for welding and brazing it was examined through the
target group surveyed from the 30 students studying in the two year
of 5-year-academic program, department of production technology
education, faculty of industrial education and technology, king
mongkut-s university of technology thonburi. The result of the
research indicated that the media evaluated by experts and subject
matter quality evaluation of computer assisted instruction for welding
and brazing was in line for the good criterion. The mean of score
evaluated before the study, during the study and after the study was
34.58, 83.33 and 83.43, respectively. The efficiency of the lesson was
83.33/83.43 which was higher than the expected value, 80/80. The
study accomplishment of the learner, who utilizes computer assisted
instruction for welding and brazing as a media, was higher and equal
to the significance statistical level of 95%. The value was 1.669
which was equal to 35.36>1.669. It could be summarized that
computer assisted instruction for welding and brazing was the
efficient media to use for studying and teaching.
Abstract: The objective of this research was to study influence
parameters affecting to mechanical property of austenitic stainless
steel grade 304 (AISI 304) with Gas Metal Arc Welding (GMAW).
The research was applying factorial design experiment, which have
following interested parameters: welding current at 80, 90, and 100
Amps, welding speeds at 250, 300, and 350 mm/min, and shield gas
of 75% Ar + 25% CO2, 70% Ar + 25% CO2 + 5% O2 and 69.5% Ar +
25% CO2 + 5% O2 + 0.5% He gas. The study was done in following
aspects: ultimate tensile strength and elongation. A research study of
ultimate tensile strength found that main factor effect, which had the
highest strength to AISI 304 welding was shield gas of 70% Ar +
25% CO2 + 5% O2 at average of 954.81 N/mm2. Result of the highest
elongation was showed significantly different at interaction effect
between shield gas of 69.5%Ar+25%CO2+5%O2+.5%He and
welding speed at 250 mm/min at 47.94%.
Abstract: Aluminothermic rail welding was from the beginning
a great success because its low price even in 1895 in Germany. This
method is now, widely used all over the world for the railways
construction, maintenance and modernization. Instructions give you
guidelines for preparing papers for conferences or journals.
After 1989, the welding needs of the potentials beneficiaries
(Romanian Railways, Urban Transportation Companies) keep raise
because of the railways maintenance and modernization necessity.
The main materials that determine the Thermit (T) composition
result from manufacturing scraps all over the country. This can help
the environment by consuming these scraps.
The Romanian need for alumino-thermic welding is now by 11300
per year, and in a favourable economical environment, this amount
can reach 30000 units.
This paper tries to show the effect of two types of modifiers
introduced in the T composition on the structure and properties of an
alumino-thermic welding.
Abstract: This paper presents an iterative algorithm to find a
inverse kinematic solution of 5-DOF robot. The algorithm is to
minimize the iteration number. Since the 5-DOF robot cannot give full
orientation of tool. Only z-direction of tool is satisfied while rotation
of tool is determined by kinematic constraint. This work therefore
described how to specify the tool direction and let the tool rotation free.
The simulation results show that this algorithm effectively worked.
Using the proposed iteration algorithm, error due to inverse kinematics
converged to zero rapidly in 5 iterations. This algorithm was applied in
real welding robot and verified through various practical works.
Abstract: Three dimensional analysis of thermal model in laser
full penetration welding, Nd:YAG, by transparent mode DP600 alloy
steel 1.25mm of thickness and gap of 0.1mm. Three models studied
the influence of thermal dependent temperature properties, thermal
independent temperature and the effect of peak value of specific heat
at phase transformation temperature, AC1, on the transient
temperature. Another seven models studied the influence of
discretization, meshes on the temperature distribution in weld plate.
It is shown that for the effects of thermal properties, the errors less
4% of maximum temperature in FZ and HAZ have identified. The
minimum value of discretization are at least one third increment per
radius for temporal discretization and the spatial discretization
requires two elements per radius and four elements through thickness
of the assembled plate, which therefore represent the minimum
requirements of modeling for the laser welding in order to get
minimum errors less than 5% compared to the fine mesh.
Abstract: Friction stir welding is a solid state joining process. High strength aluminum alloys are widely used in aircraft and marine industries. Generally, the mechanical properties of fusion welded aluminum joints are poor. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phases common in fusion welding of high strength aluminum alloys. In this review the process parameters, microstructural evolution, and effect of friction stir welding on the properties of weld specific to aluminum alloys have been discussed.
Abstract: In this study the elastic-plastic stress distribution in
weld-bonded joint, fabricated from austenitic stainless steel (AISI
304) sheet of 1.00 mm thickness and Epoxy adhesive Araldite 2011,
subjected to axial loading is investigated. This is needed to improve
design procedures and welding codes, and saving efforts in the
cumbersome experiments and analysis. Therefore, a complete 3-D
finite element modelling and analysis of spot welded, bonded and
weld-bonded joints under axial loading conditions is carried out. A
comprehensive systematic experimental program is conducted to
determine many properties and quantities, of the base metals and the
adhesive, needed for FE modelling, such like the elastic – plastic
properties, modulus of elasticity, fracture limit, the nugget and heat
affected zones (HAZ) properties, etc. Consequently, the finite
element models developed, for each case, are used to evaluate
stresses distributions across the entire joint, in both the elastic and
plastic regions. The stress distribution curves are obtained,
particularly in the elastic regions and found to be consistent and in
excellent agreement with the published data. Furthermore, the
stresses distributions are obtained in the weld-bonded joint and
display the best results with almost uniform smooth distribution
compared to spot and bonded cases. The stress concentration peaks at
the edges of the weld-bonded region, are almost eliminated resulting
in achieving the strongest joint of all processes.
Abstract: This paper reports the fatigue crack growth behaviour
of gas tungsten arc, electron beam and laser beam welded Ti-6Al-4V
titanium alloy. Centre cracked tensile specimens were prepared to
evaluate the fatigue crack growth behaviour. A 100kN servo
hydraulic controlled fatigue testing machine was used under constant
amplitude uniaxial tensile load (stress ratio of 0.1 and frequency of
10 Hz). Crack growth curves were plotted and crack growth
parameters (exponent and intercept) were evaluated. Critical and
threshold stress intensity factor ranges were also evaluated. Fatigue
crack growth behaviour of welds was correlated with mechanical
properties and microstructural characteristics of welds. Of the three
joints, the joint fabricated by laser beam welding exhibited higher
fatigue crack growth resistance due to the presence of fine lamellar
microstructure in the weld metal.